GS1000 hydraulic clutch

[Agemax]

I drilled the case and its 9mm.

thanks for that Tatu, unfortunately i no longer need that mount hole. i have no idea why on earth i thought i could use it. the angle of the pic makes it look possible but in reality it is a million miles away. i said i was tired !!!!!!

so anyway today i went to plan B and made a new plate which i am happy with. it is only a mock up so i will need to make a better one now.

here is the plate.....



and with the slave bolted on.......



5mm aluminium was used for the plate and it fits nice.
the top hole on the slave will need to be machined down but i pretty much knew that anyway. there is enough material there to mill it down and counterbore it for a 6mm allen bolt.

[tatu]

That plate is much better than the drawing and was the picture I had in mind, will you stop with ally or make a final one out of mild?

[Agemax]

That plate is much better than the drawing and was the picture I had in mind, will you stop with ally or make a final one out of mild?

i am thinking ally but my "sensible" head says i should use mild steel really.
looks wont matter as it will not be visible so shiney ally is not nessecary.
ally is easier to make but steel would be much stronger and the tapped threads would be stronger

[tatu]

ally is easier to make but steel would be much stronger and the tapped threads would be stronger

That's what I'm thinking, 5mm thickness isn't even as the thick as the diameter of the bolt so holding will always be reduced and ally reduces it further.
You want to ride your bike with a clear head, not have that nag in the back of your head of something that could'v been sorted at the bench.

[Agemax]

That's what I'm thinking, 5mm thickness isn't even as the thick as the diameter of the bolt so holding will always be reduced and ally reduces it further.
You want to ride your bike with a clear head, not have that nag in the back of your head of something that could'v been sorted at the bench.

yep, that seals it. steel it is then.
only thing with ally is i could make the plate at home, with a hole saw for the main hole. with steel i will have to get it machined, no hassle but will just take longer......

[Flatline_Racing]

I really like where this is going. I maay have to find one of these gas gas slaves for myself.

[Agemax]

I really like where this is going. I maay have to find one of these gas gas slaves for myself.

all i know is it is from a Gas Gas 400. i can find out the model and year tomorrow if you want it.

[Flatline_Racing]

That would be great! I am also running an offset sprocket so I should have a little more clearance to work with.

[Agemax]

That would be great! I am also running an offset sprocket so I should have a little more clearance to work with.

yeah i dont think this mod will work at all unless you have an offset front sprocket

[quexpress]

I really like where this is going. I may have to find one of these gas gas slaves for myself.

You and I both!
I love Adrian's set-up.

[Agemax]

You and I both!
I love Adrian's set-up.

lets all not get to excited until it actually works!!!!!!!

[Agemax]

ok, on a slow down for a bit now, going to fab the plate out of mild steel today and still waiting for the silver steel rod and GSXR clutch pusher to make the pushrod, dont you just love ebay sellers estimated delivery dates?????

so i guess i will have to think about what M/C i am going to use.....

i would like to stick to suzuki if i can as i would have a chance at getting matching levers, to go with the B6 brake M/C i have.

the stock Gas Gas M/C is tiny....

http://www.ebay.co.uk/itm/310646409967?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

but the lever looks similar to the suzuki brake lever.

i found this one off a suzuki AN250 Burghman(?) which could be ok.

http://www.ebay.co.uk/itm/111041239781?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

obviously i need one which will fit around the GS switch assembly which i dont think the Gas Gas one would, as trials bikes dont have light switches!

i would like to know the piston bore size of the Gas Gas master so i can get some idea of what i should be using but even my google search abilities have found nothing to help.

any thoughts/ideas would be appreciated thanks

[Agemax]

just in case anyone wants the info. the slave cylinder is from a 2004 Gas Gas 400EC motocrosser

[gmansyz]

Slaved?

Very interesting!!
G

[Agemax]

got the plate made now and the slave machined. it bolts right on now and clears every thing.

it is a bit close to the chain but there is a decent enough gap.
got to make the pushrod when the GSXR pusher finally arrives in the post.

Master cylinder arrived today, Suzuki AN400 burgman. matches the B6 brake master perfectly with a smaller fluid reservoir.

the only problem i have now is because the slave had to go on at an angle to clear the chain, there is enough room to bolt the hydraulic hose to the slave but not the bleed nipple.(it comes with a single banjo bolt with built in bleed nipple)
i will have to bleed the slave off the bike,through the banjo bolt which should work ok......i hope.